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2 Ceramic Fabrication-Next
2 Ceramic Fabrication-Next
Form long, wide glass pieces (window glass,sheet, tubing, rod etc)
hot rolling may applied
Flatness & surface finish may be improved by floating the molten
glass sheet on a bath of molten tin at high T followed slowly cooled
and subsequently heat treated
Glass processing
CERAMIC-Clay Products
• Clay are aluminosilicates Al2O3 & SiO3 contain chemically
bound water
• Broad in physical characteristic, chemical composition,
structure
• Impurities-various: oxide of Ba, Ca, Na, K, Fe
• May contain nonplastic ingredient
• Nonclay minerals: flint, quartz, feldspar
• Quartzrelatively hard, little change in high T, ability to form
glass
Composition
• Clay minerals play 2 roles:
1.When added water, form hydroplasticity
2.Fuse or melt over a range T dense & strong
ceramic during firing without complete melting;
desired shape
• the binder should be able to be eliminated from the compact during the
firing process without any disruptive effect water, polymers
• Poly (vinyl alcohol) (PVA high green strength) and poly (ethylene glycol)
(PEGhigh green density) are the two of the most popular binders for dry
pressing ceramics
Plastic forming
• Plasticizer is the component of a binder that keeps it soft or pliable; it
improves the rheological properties
• Mixing ceramic powder with large vol of liquid to produce a mass that
deformable/plastic under P
• The binder: water, organic liquid, complex comp to achieve required
viscosity & properties
NOTE
Slurry a suspension of ceramic particles in a liquid
• Green state: ceramic compact that is strong enough to be handled and
machined but is not fully dense and the bonds between the grains are not
strong represents a transition state between the loose powder and the
high-density sintered product ; ceramic before fired
• Slip fine ceramic powders (<10 um) that are suspended in fluid
Fabricating clay product
• Clay is mixed with water to form a plastic body & formed
to desired shape wet body
• Wet body is then dried and fired
- drying removes water from the clay controlled rate
- fire vitrifies clay
- degree of vitrification depends on firing tempterature
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CERAMIC SHAPING
3 methods in ceramic shaping:
Powder compaction: dry pressing, hot pressing, cold isostatic pressing,
etc
casting: using a mold with the ceramic as or containing of liquid or slurry
Plastic forming: using pressure to shape the green ceramic; extrusion,
injection molding etc.
Powder compaction
• Pressing of free flowing powder
• Pressure application depends on final product
• 2 types: dry pressed (i.e. without addition of binder) & pressed with the
addition of suitable binder
• uniaxially simple shape, or isostaticcally complex shape
Dry pressing
• three basic steps: filling the die, compacting the contents, and
ejecting the pressed solid
• A particle size 20 and 200 µm; a high volume fraction of small
particles s problems with flow and sticking of the punches.
• During pressing the powder particles must flow between the
punches uniformly filled.
• In a double-action press top and bottom punches are
movable
• Product example: brick
• bottom punch is in the low position a cavity the cavity is filled with free
flowing powder ; the powder is struck off level with the top of the die.
The top punch descends and compresses the powder either to a
predetermined volume/set pressure.
• After pressing, both punches move upward The compact is then ejected
Hot pressing
• Pressing performed at high temperatures
• The die assembly is contained within a high temperature furnace
• During hot pressing the ceramic powders may sinter together to form a high-
density component.
• the ADVANTAGES of this process:
1 The powder does not have to be of the highest quality.
2 Large pores that are caused by non uniform mixing are easily removed.
3 densify at temperatures lower (typically half the melting temperature of the
material) than those needed for conventional pressure less sintering.
4 densify covalently bonded materials such as B4C, SiC, and Si3N4 without additives
• Graphite is the most widely used
die material (up to 2200°C, 10 -
30 Mpa)
• Graphite properties:
1 easy to machine
2 cheap
3 strength increase with T
4 good creep resistance
5 excellent thermal conductivity
6 low coeff of thermal expansion
• DISADVANTAGE :
1 Die for high T is expensive and do
not generally last long.
2 limited simple shape: flat plates,
block, cylinder
Cold isostatic pressing-CIP
• apply of hydrostatic pressure to a powder in a
flexible container.
• The advantage of applying pressure in all directions
more uniform compaction of the powder and
more complex shapes
• Can be performed either with or without applied
heat.
WET BAG CIP PROCESS
ADVANTAGES:
• Wide range of shapes and sizes can be produced
• Uniform density of the pressed product
• Low tooling costs
DISADVANTAGES:
• Poor shape and dimensional control (particularly for
complex shapes)
• Long cycle times (typically between 5 and 60
minutes) low production rates
Casting ceramic
• In Tr, require slurry ceramic powder particles to be suspended in a
liquid
• 2 type: slip casting & tape casting
• S lip casting slurry is poured into porous mold that remove the liquid,
leave a particulate compact in the mold
• Tape casting to make thick film/sheet
Slip casting
• The slip is poured into a mold (usually plaster of Paris-
2CaSO.4H2O) that has been made by casting round a
model of the required shape
• The mold allow for the shrinkage of the cast ceramic
on drying and sintering.
• The fineness of the powder (in the slip) and the
consequent high surface area ensure that settling
does not occur.
• Na silicate (or soda ash) is added to the slip to
deflocculate the particles. The water passes, via
capillary action, into the porous plaster leaving a layer
of the solid on the wall of the mold. Once a sufficient
thickness has been cast, the surplus slip is poured out
and the mold and cast are allowed to dry.
• Drain slip casting the process’s terminated when desired
thickness reached, pour out the excess slip.
• After dried, the mold is disassembled
• Characteristic the Slip high specific gravity, very fluid &
pourable
• sanitary lavatory ware, art objects
• Slip casting is a low cost way to produce complex shapes
• method for the production of teapots, jugs, and large articles (whitewares)
• One of the t signs of slip casting ceramic is that it is hollow.
• Another variant of the slip casting process is solid/tape casting slip is
continually added until a solid cast is made. These items will not be
hollow—relatively, they will be heavier.
• Characteristic slip: high specific gravity, very fluid, pourable (depend on
solid to water ratio), free of bubble, low drying shrinkage & high strength
• Mold properties quality of casting
• Usually plaster of paris ecomonical, easy to fabricate, reusable
• Solid casting water from slip is absorbed into the mold when
poured, leaving solid layer on the mold wall (thickness, f=(t))
• May continue until entire mold cavity becomes solid
extrusion